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Designation: D 2657 07
2. Referenced Documents
2.1 ASTM Standards: 2
F 1056 Specification for Socket Fusion Tools for Use in
Socket Fusion Joining Polyethylene Pipe or Tubing and
Fittings
F 2620 Practice for Heat Fusion Joining of Polyethylene
Pipe and Fittings
1. Scope
1.1 This practice describes general procedures for making
joints with polyolefin pipe and fittings (excluding polyethylene
pipe and fittings) by means of heat fusion joining techniques in
either a shop or field environment. These procedures are
general ones. Specific instructions for heat fusion joining are
obtained from product manufacturers. See Practice F 2620 for
heat fusion joining of polyethylene pipe and fittings.
1.2 The techniques covered are applicable only to joining
polyolefin pipe and fittings of related polymer chemistry, for
example, polypropylenes to polypropylenes, or polybutylenes
to polybutylenes. Material, density, and flow rate shall be taken
into consideration in order to develop uniform melt viscosities
and formation of a good fusion bond when joining the same
material to itself or to other materials of related polymer
chemistry.
1.3 Parts that are within the dimensional tolerances given in
present ASTM specifications are required to produce sound
joints between polyolefin pipe and fittings when using the
joining techniques described in this practice.
1.4 The values stated in inch-pound units are to be regarded
as the standard. The values given in parentheses are for
information only.
1.5 The text of this practice references notes, footnotes, and
appendixes which provide explanatory material. These notes
and footnotes (excluding those in tables and figures) shall not
be considered as requirements of the practice.
1.6 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. See specific safety
precautions in 3.1.1, 5.2, 8.2.3.1, Note 8 and Note 9, and A1.1.
3. Summary of Practice
3.1 Heat-fusion joining uses a combination of heat and force
resulting in two melted surfaces flowing together to produce a
joint. Fusion bonding occurs when the joint cools below the
melt temperature of the material. There is a temperature range
within which any particular material is satisfactorily joined.
The specific temperature used requires consideration of the
properties of the specific material, and the joining environment.
With Techniques II or III (3.3.2 or 3.3.3), there is also an
appropriate force to be applied which depends upon the
material, the fusion equipment being used, and fusion temperature. See Practice F 2620 for heat fusion procedure for polyethylene pipe and fittings.
3.1.1 Electrically powered heat fusion tools and equipment
are usually not explosion proof. When performing heat fusion
in a potentially combustible atmosphere such as in an excavation where gas is present, all electrically powered tools and
equipment that will be used in the combustible atmosphere
shall be disconnected from the electrical power source and
operated manually to prevent explosion and fire. For the
heating tool, this requires bringing the heating tool up to or
slightly above temperature in a safe area, then disconnecting it
from electrical power immediately before use. This procedure
is limited to smaller sizes where heating is accomplished
before the heating tool drops below acceptable temperature.
1
This practice is under the jurisdiction of ASTM Committee F17 on Plastic
Piping Systems and is the direct responsibility of Subcommittee F17.20 on Joining.
Current edition approved May 1, 2007. Published May 2007. Originally
approved in 1967. Last previous edition approved in 2003 as D 2657 03.
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standards Document Summary page on
the ASTM website.
Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
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3.3.3 Procedure 3, Saddle FusionThe saddle-fusion technique involves melting the concave surface of the base of a
saddle fitting, while simultaneously melting a matching pattern
on the surface of the pipe, bringing the two melted surfaces
together and allowing the joint to cool while maintaining the
appropriate applied force. See Fig. 3.
5. Operator Experience
5.1 Skill and knowledge on the part of the operator are
required to obtain a good quality joint. This skill and knowledge is obtained by making joints in accordance with proven
procedures under the guidance of skilled operators. Evaluate
operator proficiency by testing sample joints.
5.2 The party responsible for the joining of polyolefin pipe
and fittings shall ensure that detailed procedures developed in
conjunction with applicable codes and regulations and the
manufacturers of the pipe, fittings, and joining equipment
involved, including the safety precautions to be followed, are
issued before actual joining operations begin.
6. Apparatus: General Recommendations
6.1 Heating ToolThe tool may be heated by gas or
electricity. Gas-fired heaters for 2in. IPS and smaller socket
and butt fusion joints only, shall have heat sinks of sufficient
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capacity to prevent excessive draw down of the tool temperature, and are used only in above-freezing conditions. Electric
heating plates maintain consistent fusion temperatures when
provided with an adequate power source. Electric heating
plates for general fusion use shall be controlled thermostatically and most are adjustable for a set point temperature
ranging from 300 to 575F (150 to 300C). Some tools may
have a fixed set point for a particular application.
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7.2.4 Bring the preheated tool faces into contact with the
outside surface of the end of the pipe and the inside surface of
the socket.
7.2.5 Heat the pipe end and the fitting socket for the time
required to obtain a proper melt. Proper melt is a function of
material, time, tool temperature, and the size of the parts. Pipe
and fittings of larger diameters require more time to reach the
proper melt consistency than those of smaller diameters.
Underheated or overheated materials will not form a good
bond.
7.2.6 At the end of the heating time, simultaneously remove
the pipe and fitting straight out from the tool, using a snap
action. Immediately insert the pipe straight into the socket of
the fitting so the rounding clamp is flush against the end of the
fitting socket. Hold or block the joint in place until the melts of
the mating surfaces have solidified. The exact cooling time
depends on the size of the pipe and the material being fused.
7.2.7 Remove the rounding clamp, and inspect the melt
pattern at the end of the socket for a complete impression of the
rounding clamp in the melt surface. There shall no gaps, voids,
or unbonded areas. Clean the heating tool of any residual
material using a wood stick or a clean, dry, oil-free, lint-free,
non-synthetic cloth. Take care not to damage the heating
surfaces. Plastic left on the tool tends to char when reheated,
causing a loss of heater efficiency and joint contamination.
7.2.8 Allow for extremes in weather when making field
joints. Heating times, operation of alignment jig, dimensional
changes, and the like, are affected by extreme conditions.
7.3 TestingEvaluate sample joints in order to verify the
skill and knowledge of the fusion operator. Cut joints into
straps, (see Fig. 4) and visually examine and test for bond
continuity and strength. Bending, peeling, and elongation tests
are useful for this purpose.
8.1 Apparatus:
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D 2657 07
8.2.4 Bring the piping components together and check for
high-low alignment, and out-of-roundness. Adjust as required.
Re-face after adjustment. The ends of the piping components
shall be square to each other around their full circumference.
8.2.5 Place the heater plate between the component ends,
and move the component ends against the heater plate with
sufficient force to ensure complete circumferential contact
against the heater plate. Hold the components against the
heater plate briefly, using limited force to ensure that proper
contact with the plate has been made. Release the force, but
hold the components against the heater plate until an appropriately sized bead of molten plastic develops circumferentially
around each component end as a result of the thermal expansion of the material. Do not push the components into the
heater plate as the melting progresses.
8.2.6 Move the melted component ends away from the
heater plate, and remove the heater plate. Quickly inspect the
melted surfaces per 8.2.1. If the melt is acceptable, immediately bring the melted ends together with enough force to roll
both component melt beads over to the pipe surface around the
entire circumference of the joint. When the bead touches the
pipe surface, stop moving the component ends together, but do
not release the force. Hold the force on the joint until the joint
has cooled.
8.2.6.1 Do not use excessive or insufficient force. If the
components are brought together with too much force, all
molten material may be pushed out of the joint and cold
material brought into contact forming a cold joint. If too little
force is used, only the melt in the beads may be fused together
and, as the molten material in the joint cools and contracts,
voids or non-fused areas may be formed. If the softened
material sticks to the heater plate, discontinue the joining
procedure. Clean the heater plate, re-square the component
ends, and repeat the process from the beginning (8.2.2).
8.2.6.2 Inspect the component ends quickly when the heating tool is removed. The melt should be flat. A concave melt
surface indicates unacceptable pressure during heating. If a
concave melt surface is observed, do not continue. Allow the
component ends to cool, and start over from 8.2.1.
8.2.6.3 For any pipe size and wall thickness, the actual
fusion joining force is determined by multiplying the interfacial pressure by the area of the pipe end. To determine a fusion
pressure gauge setting for hydraulic butt fusion machines, the
force is divided by the area of the hydraulic cylinders that
move the fusion machine carriage. The hydraulic fusion
machine gauge pressure setting may need to be increased to
overcome internal machine friction drag or to provide additional force to move pipes attached to the butt fusion machine.
8.2.7 Allow the assembly to stand at least until cool before
removing the clamps or other aligning device (Note 7). Do not
subject the joint to high stress until it has cooled to less than
approximately 130F. Do not apply internal pressure until the
joint and surrounding material have reached ambient air
temperature.
8.2 Procedure:
8.2.1 Bring the heater plate surfaces to proper temperature.
8.2.2 Clean the inside and outside of the components (pipe
or pipe and fitting) to be joined. Remove all foreign matter
from the surface of the component where it will be clamped in
the alignment jig.
8.2.3 Align each component with its alignment jig clamp,
and close the clamp. Check component to component alignment, adjust as needed, and face off the ends.
8.2.3.1 Take care when placing pipe or fittings in the
alignment jig. Pipes shall be aligned before the alignment
clamp is closed; however, do not force the pipe into alignment
by pushing it against the side of an open alignment jig clamp.
Copyright ASTM International
Provided by IHS under license with ASTM
No reproduction or networking permitted without license from IHS
NOTE 7The joint is usually cool enough to remove from the alignment jig if a bare hand can be held against the beads without discomfort
(less than approximately 130F). Further cooling is recommended prior to
ditching the pipe.
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9.2.2 Clean the mating surfaces of the pipe and the concave
surface of the fitting base and roughen the mating surfaces.
Emery or garnet cloth of 50 to 60 grit is used to remove the
tough outer surface skin. It is essential to remove the surface
skin completely without altering the contours of the mating
surfaces and to keep the surface clean. Remove dust and
particles from the surface after roughing with a clean, dry,
oil-free, lint-free cloth.
9.2.3 Install the alignment jig on the pipe. For smaller pipe
sizes, install a bolster plate under the pipe to provide additional
support.
9.2.4 Install the fitting in the alignment jig. Press the fitting
against the pipe to align the fitting base to the pipe, then secure
the fitting in the alignment jig.
9.2.5 Place the heater on the pipe and press the fitting
against the heater to obtain a melt on both the pipe and the
fitting.
8.2.8 Visually inspect the joint against recommended appearance guidelines. The beads should be uniformly shaped
and sized all around the joint.
8.3 TestingEvaluate sample joints to verify the skill and
knowledge of the fusion operator. In some cases, butt-fusion
joints can be nondestructively examined using ultrasonic
equipment to detect voids or other discontinuities. Visually, the
width of butt fusion beads should be 2 to 2-1/2 times the bead
height above the pipe, and the beads should be rounded and
uniformly sized all around the pipe circumference. The
v-groove between the beads should not be deeper than half the
bead height above the pipe surface. When butt fusing to
molded fittings, the fitting-side bead may display shape irregularities such as minor indentations, deflections and nonuniform bead rollover from molded part cooling and knit lines.
In such cases, visual evaluation is based mainly on the size and
shape of the pipe-side bead. For destructive tests, cut joints into
straps (see Fig. 4), visually examine, and test for bond
continuity and strength. Tests that have been found useful for
this purpose include inside face bend, outside face bend, tensile
elongation, torque, and impact. Quantifiable data may be
obtained by the use of laboratory procedures and comparing
data against that from control samples.
NOTE 9When saddle fittings are fused to pipes that are under
pressure, it is important that the surface melt be obtained quickly without
too much heat penetration. Otherwise, the pipe may rupture from internal
pressure. Consult the manufacturer for specific recommendations for
fusing saddle fittings to pipe under pressure.
NOTE 10If a suitable melt pattern has not been achieved, do not
reheat; however, continue with the fusion and apply the fitting to the pipe.
When the joint has cooled, remove the alignment jig, cut off the top of the
fitting to prevent use, and start over at another location.
10. Keywords
10.1 butt fusion; fitting; heat fusion; joining; pipe; polybutylene; polyolefin; polypropylene; saddle fusion; socket fusion
9.2 Procedure:
9.2.1 Bring heater plate and faces to proper temperature.
ANNEX
(Mandatory Information)
A1. COLD WEATHER PROCEDURES
when cutting the straps on coils of pipe because the outside end
of a coil may spring out when the strapping is removed.
A1.2 Preparation for Socket, Saddle, and Butt Fusion
Joining:
A1.2.1 Wind and PrecipitationThe heating tool should be
shielded in an insulated container to prevent excessive heat
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IPS pipe), the pipe may barely contact the heating surface.
Longer heating cycles are used so that the pipe first expands
(from tool heat) to properly contact the heating tool, then
develops complete melt. The length of cycle necessary to
obtain a complete melt pattern will depend not only on the
outdoor (pipe) temperature but wind conditions and operator
variation. Avoid cycles in excess of that required to achieve a
good melt pattern. To determine the proper cycle time for any
particular condition, make a melt pattern on a scrap piece of
pipe, using the heating cycle as instructed by the pipe manufacturer. If the pattern is incomplete (be sure rounding rings are
being used), try a 3-s longer cycle on a fresh (cold) end of pipe.
If the melt pattern is still not completely around the pipe end,
add an additional 3 s and repeat the procedure. Completeness
of melt pattern is the key. Keep the heater dry at all times.
Check the temperature of the heating tool regularly and keep
the heating tool in an insulated container between fusions.
loss. Shield the pipe fusion area and fusion tools from wind,
snow, and rain by using a canopy or similar device.
A1.2.2 Pipe and Fitting Surface PreparationThe pipe and
fitting surfaces to be joined or held in clamps should be dry
and clean and free of ice, frost, snow, dirt, and other contamination. Regular procedures for preparation of surfaces to be
joined, such as facing for butt fusion and roughening for saddle
fusion should be emphasized. After preparation, the surfaces
should be protected from contamination until joined. Contamination of the area to be fused will likely cause incomplete
fusion. Frost and ice on the surfaces of the pipe to be clamped
in either a cold ring or alignment jigs may cause slippage
during fusion. Inspect coiled pipe to see if it has flattened
during storage which could cause incomplete melt pattern or
poor fusion. It may be necessary to remove several inches at
the pipe ends to eliminate such distortion. Pipe may have a
slight toe-in or reduced diameter for several inches at the end
of the pipe. The toe-in may need to be removed before butt
fusing to a freshly cut pipe end, or to a fitting.
A1.2.3 HeatingWork quickly once pipe and fitting have
been separated from the heating tool, so that melt heat loss is
minimized, but still take time (no more than 3 s) to inspect both
melt patterns. Keep the heater dry at all times. Check the
temperature of the heating tool regularly with a pyrometer.
Keep the heating tool in an insulated container between
fusions. Do not increase heating tool temperature above the
specified temperature setting. Gas-fired heating tools are used
only in above freezing conditions.
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